1 Introduction To Space Frames
1 Introduction To Space Frames
1.1. Introduction
Space structures are a leaf taken from Nature. Natural forms possess exceptional
rigidity and use minimum materials to maximum structural advantage. To quote
Makowski, ‘Natural forms act in the direction of minimum effort’. In 1940, Le
Recolais, a well-known exponent of space frames, drew attention to the geodesic
type of spherical surfaces that characterize the bone skeletons of Radia tuscaretta
globosa. Man has not been slow in copying these examples drawn from Nature.
It may not perhaps be well known that Alexander Graham Bell, the inventor of the
telephone, was one of the first to appreciate the merits of space frames and apply
them in actual construction. In fact, he built one of the early versions of a flying
machine using a multi-layered space frame concept. As the saving in weight is more
critical in aircraft structures than in buildings, it is not surprising that the earliest
efforts to take advantage of the lightness of space frames, stemming from their
structural efficiency, were in building flying machines. It is in this context that the
Wright brothers discovered the possibilities offered by the tetrahedron.
Historically, the earliest space structures to be built were the domes pioneered by
the German Engineers Schwedler and Zimmermann in the nineteenth century.
Zimmermann achieved a span of 361 ft for an Exhibition Structure built at Lyons as
early as 1894. The Schwedler-type dome built over the Civic Centre at Charlotte,
North Carolina, USA, immediately after the Second World War had a clear span of
332 ft. These indeed were remarkable feats for those times. These early experiments
were all but forgotten until 1937, when Dr Mengeringhausen revived interest in
space frames. He realized that the promotion of space frames on a large scale would
be possible only if the system lent itself to factory production and field assembly. To
achieve these twin objectives, it was necessary to reduce variety and develop a means
of easy assembly. Ideally, a space frame must consist of members of identical length,
although a practical compromise is often to settle for as few different lengths
as possible. Dr Mengeringhausen’s pioneering topological studies were aimed at
reducing variety and his invention of the MERO connector elegantly solved the
problem of easy assembly. With these developments, Mengeringhausen was able
to successfully commercialize space frames in 1942. His universal MERO node
connector (Fig. 1.1) can accept as many as 18 members at different angles in tapped
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Welded seam
Dowel pin
Cap
Node
Threaded bolt
Cap
Fig. 1.1. The MERO system. (Reproduced with permission from Hiroyuki [1.13])
holes distributed over its surface. It became possible, for the first time, to build
space frames out of precise mass-produced factory-made components that could be
assembled in simple Mechano fashion. Transportation posed no problems, because
the individual components were of manageable size and weight. Complex space
frames can be built even at remote locations using relatively unskilled labour.
Mengeringhausen’s work triggered similar developments all over the world. The
following years witnessed a proliferation of proprietary systems. Octatube, Nodus,
Unistrut, Unibat, Space Deck and Triodetic and their variations are among the
systems that were developed during this period in different parts of the world. Some
of these systems are described in later paragraphs in this chapter.
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In the 1976 American Society of Civil Engineers report entitled Lattice Structures:
State-of-the-Art Report [1.2] space frames are referred to as lattice structures and are
defined as:
… a structural system in the form of a network of elements (as opposed to a
continuous surface) … another characteristic of lattice structural systems is
that their load-carrying mechanism is three dimensional in nature.
A distinction is sometimes drawn between space frames and space trusses.
According to this terminology, space trusses are those systems that are pin-jointed,
while the term space frame is reserved for structures with rigid joints. In this chapter,
following the IASS Working Group’s report, ‘space frame’ is used as a generic term,
of which space trusses are merely a subset.
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1.6. Members
The members of a space frame are either of aluminium or steel. Aluminium
members are of light weight but are more expensive. The large majority of space
frames use members of steel with a yield strength ranging from 210 to 450 MPa. The
tubes may be electrically resistance welded or seamless.
The Allied & Conduit Corporation, USA, manufactures a proprietary electrical
resistance welded steel tube known as a Flocoat tube, with a yield strength of
450 MPa. The unique process involves the use of steel strips cold-rolled into a
precision tube which is continuously hot-dip galvanized followed by the on-line
application of a protective coat to make it rust-proof. This process is shown
schematically in Fig. 1.2.
The protective coats applied on-line over the galvanizing consist of a chromate
conversion coat followed by a clear polymer coating. This proprietary tube has an
edge over ordinary steel tubes in two respects:
• it has very high corrosion resistance
• it has a higher yield strength of 450 MPa.
When Flocoat tubes are not available, it is recommended that steel tubes and
connectors be galvanized and powder-coated to the colour of the client’s choice if
superior corrosion resistance and aesthetics are desired.
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High-quality steel
Water quenched
Chromate
substrate
application
Additional
exterior coatings
Tube welding
In-line Flo-Coat
Tube forming zinc galvanizing
Steel coil
• A threaded spherical ball of hot forged steel with as many as 18 tapped holes, at
different angles, distributed evenly over its surface, to receive tubular members
at different angles. The sphere has flat surfaces around the threaded holes to
improve the seating of the spanner sleeve. The holes are precisely drilled so that
the centre lines of the tubes at a node meet at the centre of the sphere.
• A bolt, which is inserted through a hole in the tubular member and passes
through a cone welded to the end of the tube.
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(a)
Tube
A A
Holes
Member
SECTION A–A
Holes B Nut
Weld
Section B–B
Weld
Bolt
Base Holes
plate B
Joint
Web
member
(b) 2Q
2Q 2Q
Web
member
Chord
member
2Q
2Q 2Q
2Q 2Q
Chord
member Case 1
4Q 4Q Web
member
2Q
2Q 2Q
Chord
2Q 2Q member
2Q
4Q 4Q
Fig. 1.3. The Octatube system: (a) the components; (b) assembly patterns of the nodes. (Reproduced
with permission from Hiroyuki [1.13])
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be connected is fitted at its ends with threaded solid props by welding. Working from
inside the cup, high-strength bolts, normally of 8.8 or 10.9 grade, according to the
British Standard Code, are driven into the threaded prop by means of a torque
wrench. Coning of the ends of the tube is resorted to if tubes of large diameter are to
be accommodated without congestion (Fig. 1.6) over the surface of the cup. If the
tension to be transmitted to a node exceeds the permissible tensile strength of the
node, the member is carried through the node by using a threaded rod to connect the
ends of the tubes (see Fig. 1.6). Being hollow, the Tuball node tends to be lighter
than a solid forged node. It is also less expensive, because spheroidal graphite costs
less than forged steel. The Tubal node has been used successfully for building
numerous space frames in India, the United Arab Emirates and the Far East using
relatively unskilled labour.
Fig. 1.4. The space frame over the arrival hall at Bangalore Airport, Bangalore, India
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Alien head
bolt
Node
Bolt
X X
Prop
Tube
Prop
Tube
Weld
Cup
Tube
Bolt
Prop
Tuball node
Threaded bolt
Coned ends
Fig. 1.6. A Tuball node with a threaded rod and coned props
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The space frame over the Gatwick railway station concourse in England is a good
example of the application of the Nodus system (Fig. 1.8). The design brief called for
a 63 m by 33 m concourse with no interior columns. The pre-set parameters and the
need to integrate the concourse with the grid and orientation of the British Airport
Authority’s building at the concourse level limited the options open to the architect
and structural engineer. Causing minimum inconvenience to passengers and to
British Rail was a major consideration that led to the choice of the Nodus space
frame. Assembling the space frame on the ground and lifting it into position was not
feasible at Gatwick due to the restricted space available. The structure was therefore
assembled in situ on scaffolding.
This multi-layer space frame utilized 84 t of structural hollow sections (88.9 mm ¥
3.2 mm and 114.3 mm ¥ 6.3 mm circular hollow sections; 120 mm ¥ 120 mm ¥ 8.0 mm
rectangular hollow sections), mostly of grade 43C with a small amount of grade 50C
steel. In total 725 nodes were used. The engineer for the project was Mr F. S. Proctor,
Chief Engineer, British Rail, Southern Region, the main contractor was Cementation
Construction Ltd, and the steelwork subcontractor was Fairfield Malery Ltd. More
detailed information on the project is available elsewhere [1.9].
Fig. 1.7. The Nodus joint. (Reproduced with permission from Hiroyuki [1.12])
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Fig. 1.8. The Nodus space frame over the concourse of the Gatwick railway station
Fig. 1.9. The Triodetic joint. (Reproduced with permission from Hiroyuki [1.13])
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(a)
Diagonal
member Weld
Boss
Diagonal
member
Weld
Weld
A Weld Boss
(b)
Top chord angles
Bolt
Diagonal
Coupler
Forged boss
Fig. 1.10. The Space Deck unit: (a) the components; (b) the standard assembly. (Reproduced with
permission from Hiroyuki [1.13])
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Fig. 1.11. The Unibat system. (Reproduced with permission from Hiroyuki [1.13])
inserted into the slot with slight pressure. The central stud and retaining washer hold
the assembly together. A hub can accommodate 12 members. It is claimed that the
connector can be used with steel as well as aluminium tubes. It is stated that if steel
tubes conform to SAE 1010 and SAE 1020 (US designation) or 65ST6 (Canadian
designation), there is no risk of electrolytic corrosion [1.10]. Most of the structures
built using this system consist of aluminium tubes and aluminium connectors [1.11].
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Fig. 1.12. The platform shelter at Thirumailai Station, LUZ, Chennai, India
Fig. 1.13. The dome over the exhibition hall at Pragati Maidan, for the Trade Fair Authority, New
Delhi, India
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Fig. 1.14. The space frame over the domestic cooking gas bottling plant, for the Indian Oil
Corporation, Cuddapah, India
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9000
9000
9000
9000
Arches
9000
9000
9000
9000
9000
4500
(a)
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Fig. 1.16. The roof of the Maritime Museum built for the port of Singapore Authority by L&M Prestressing PTE Ltd: (a) the frame plan; (b) cross-section
18 STEEL SPACE FRAMES
bracings comprise the factory-made inverted pyramid. Forged pieces at the four
corners and an apex piece at the bottom permit the modules to be connected
together by means of high-strength friction bolts. Modular units are quicker to
assemble in the field and they eliminate expensive node connectors.
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roofing applications the fabric may be reinforced using cables and supported on
poles or suspended from overhead cables.
The most outstanding application of cable-reinforced fabric structures suspended
from overhead cables is the Haj Terminal at the Abdul Aziz International Airport at
Jeddah, which was built to accommodate the unusually high traffic during the Haj
Pilgrimage [1.15]. The terminal covers 105 acres, has a covered area of 500 000 m2
and can accommodate 50 000 pilgrims. Designed by Skidmore, Owings and Merril,
the terminal comprises 210 tent-shaped roofs, each 45 m by 45 m in plan, formed
from suspended, cable-reinforced, Teflon-coated, fibreglass fabric (Fig. 1.15). The
modules, which are catenoids on square ground plans, reflect the vernacular tent
architectural tradition. The translucent, heat-insulating fabric lets in diffused light
and provides a comfortable ambience in the desert. However, Teflon-coated
fibreglass fabric is expensive, and PVC-coated polyester, which is self-extinguishing,
meets all the code requirements and is often preferred as a cheaper alternative.
Cable-reinforced fabric structures similar to those used to roof the Haj Terminal
involve non-developable surfaces that pose several complex problems. These relate
to the development of fabric cutting patterns and sealing of the seams. These
problems may be overcome by draping the pretensioned fabric over a developable
cylindrical surface such as a barrel vault, as was done for two structures built for the
Port of Singapore Authority to house a maritime museum and an exhibition hall.
These structures involve two braced cylindrical barrel vaults of size 27 m ¥ 57.8 m
and 31.2 m ¥ 83.8 m. The structural arrangement adopted was the same for both
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vaults. The barrel vaults involve double-layered arches spaced 9 m apart (Fig. 1.16).
The structural designs of L&M pre-stressing were proof-checked by the first author
for Permafab Pty Ltd, Australia, who supplied the Teflon-coated, glass-fibre fabric
for the project. A view of the finished museum is shown in Fig. 1.17.
The imaginative combination of space frames, cable-stays and fabrics opens up an
unlimited array of possibilities for developing elegant and cost-effective solutions
for enclosing large column-free spaces for a diversity of applications.
1.16. References
1.1. Analysis, design and realization of space frames: a state-of-the-art report. Bulletin of the
International Association of Shell and Spatial Structures, Special Issue, 1984, 15(84/85).
1.2. TASK COMMITTEE ON LATTICED STRUCTURES, COMMITTEE ON SPECIAL STRUCTURES,
COMMITTEE ON METALS, STRUCTURAL DIVISION. Latticed structures: state-of-the-art
report. Journal of the Structural Division, ASCE, 1976, 102(ST11).
1.3. RAJARAMAN, A., APPA RAO, T. V. S. R, KHADAKKAR, A. G. and RAMASWAMY, G. S.
Minimum weight designs of parabolic antennas. Proceedings of the 2nd International
Conference on Space Structures, University of Surrey, Guildford, 1975, pp. 804–809.
1.4. LACOPULOS, A. J. Space frames for multiple antenna reflecting panels. Proceedings of the
International Conference on Space Structures, University of Surrey, Guildford, 1966, pp.
1134–1143.
1.5. MEDWADOWSKI, S. J. Space frames in architecture and science. Bulletin of the International
Association for Shells and Space Structures, 1996, XXVII-3(92/93); 1997, XXVIII-1, 7–12.
1.6. EEKHOUT, M. Architecture in Space Structures, UITGEVERIJ 010, Delft, 1989, p. 85.
1.7. MERO – Raumstruktur GmbH Co., Würzburg, Postfach 6169, D-8700 Würzburg, Germany.
1.8. BRITISH STEEL CORPORATION. NODUS Space Frame Grids. Part 3: Construction,
Structural Advisory Service, Tubes Division, Croydon, 1984.
1.9. BRITISH STEEL CORPORATION. Tubular Structures 34, Structural Advisory Service, Tubes
Division, Corby.
1.10. FENTIMAN, H. G. Development in Canada in the fabrication and construction of three-
dimensional structures using the triodetic system. Proceedings of the First Conference on
Space Structures, University of Surrey, Guildford, 1966, pp. 1073–1082.
1.11. ELLIOT, A. W. Triodetic domes. In: Z. S. Makowski (ed.) Analysis, Design and Construction
of Braced Domes, Granada, London, 1984, ch. 25.
1.12. KAWAGUCHI, M. A review of the recent development of steel space structures in Japan.
Bulletin of the International Association for Shell and Spatial Structures, 1988, XXIX-1(96).
1.13. TOMATSURI HIROYUKI. Space structure forms and systems, M.Phil. thesis, University of
Surrey, Guildford, 1994, ch. 4.
1.14. INSTITUTUS FÜR LEICHTE FLÄCHEN TRAGWERKE. IL 16: Zelte [Tents], University of
Stuttgart, 1976.
1.15. GOLDSMITH, M. Effects of scale on long span roofs. Proceedings of the 3rd International
Symposium on Wide Span Structures, University of Stuttgart, 1985, vol. 1, pp. 1–4.
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